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1、原文:design of fault diagnosis monitor system for the locomotive bearings based on dsp technologyabstractthe rolling bearing is one of the key parts of the locomotive running components, because it condition is directly related to the performance and safety of locomotive. in this paper, the monitor sy
2、stem for the locomotive bearings based on dsp tms320lf2407a is designed. this system diagnoses the rolling bearing fault using vibration analysis method. it is based on comprehensive resonance demodulation and fast fourier transform technique, and it adopts related methods to handle the result of th
3、e fft. it effectively improves the response characteristics, sensitivity, differentiate and measurement accuracy of the bearing failure monitor system, and it can fulfill the monitor and prediction of the transient fault in the course of the locomotive running.key words: resonance demodulation techn
4、ology; digital signal processor; related methods i. introductionthe higher safety is required to the trains because its speed is raised constantly. bearing fault is one of the major factors causing eventful traffic accidents and affecting rail safety. currently the railway system usually uses the be
5、aring temperature detector to monitor the locomotive bearing condition. theoretical analysis and a lot of practice show that the bearing temperature detector can prevent accidents from occurring to some extent, but most of the bearing fault is not sensitive to temperature. when the temperature of th
6、e bearing is beyond the range and the system gives an alarm, the worse damage of the bearing has occurred, and even the incident had happened. therefore, to find the fault more early and accurately, the more advanced monitoring means must be adopted. most of the bearing fault is very sensitive to vi
7、bration signal. the fault can cause vibration of the bearing increased. compared with monitoring the temperature of bearing, the analysis and processing results to the vibration signal has more advantage than the temperature means. ii. system composing and work process based on the need, the monitor
8、 of the bearing fault monitoring system to the locomotive bearing sets two detections: itineration detections and fixed detections. the itineration detection is used in the normal conditions, and the fixed detection is used for the continuous monitoring of the fault bearing. the system adopts specia
9、l composite sensor to collect the vibration of the bearing and the temperature signal at the same time. after the data processing, the corresponding fault levels and rise in temperature are got. the data acquisition unit is designed in this system. alarm information will be transmitted to all carria
10、ges through interfaces so that the staff can handled in time, and the same time, the fault data and the related information of the train such as the current location and speed will be transmitted to the dispatch center through gps, which is convenient to adopt corresponding measures. the system bloc
11、k diagram is in fig. 1.dispatch centergsm systemindustry computerinstrument for datainstrument for fault diagnosis instrument for fault diagnosisinstrument for fault diagnosisfig.1 system block diagramiii. the key technology of the design for the monitoring systema. the spectrum analysis means for d
12、iagnosing bearing faultunder normal circumstances, all parts of the rolling bearing (inner circle, outer circle, roller, holding frame) will retain the stable relative movement state. if the surface of some element (except for holding frame) has crack, and this crack is in the surface of the rolling
13、 adjacent component, the instantaneous vibration impulse must be produced.assumed that the number of the roller in the bearing is z; the diameter of the roller is d; the average diameter of the bearing inner circle and the bearing outer circle (the diameter of the roller revolution path) is d; the f
14、requency of the bearing rotation is f0. assumed that the inner circle is fixed and the outer circle is circumvolved, the vibration frequency brought by the surface defects of different bearing components can be derived.these frequencies can be called the fault characteristics frequency of the inner
15、circle, outer circle and the roller.compound sensortemperaturesignalfault vibration signaldsp digit signal processorenvelop detectionenvelop signalfrequency band pass filtertemperature signal processingfig.2 signal pretreatmentb. resonance demodulation technologywe can collect vibration signal using
16、 the resonance of the bearing components, and detect the envelope of the fault signal using envelop detector, which can fulfill the analysis to the fault character. this is called “resonance demodulation technology”. the component surfaces such as the inner circle, the outer circle and the roller of
17、 the rolling bearing are easily damaged in local place in the course of operation (such as pitting and peeling off, cracking, scratching etc.). if the surface of some bearing components have local damage and the rollingobject presses the fault dot in the course of carried operation, it must bring im
18、pact. but the impact lasts a short time, and the frequency range of the energy divergence is wide, so the energy within the scope of vibration frequency is small. due to the wide bandwidth of the impulse, it is certainly that it includes high frequency intrinsic vibration inspiring by intrinsic freq
19、uency of the inner circle, outer circle, roller, holding frame on rolling bearings. the resonance demodulate signal is separated by band-pass filter of center frequency equal to its intrinsic frequency. then the envelope demodulation is carried through to there attenuation oscillatory wave using sof
20、tware or circuit, the frequency component of the high frequency attenuation vibration is wiped off. we only obtain low-frequency envelope signal with the information of the fault character. the spectrum analysis of the envelope signal is carried through by digital signal processor, we can obtain ver
21、y high frequency resolution ratio and can easily find the frequency of the corresponding fault impact, thereby we can fulfill to diagnose to the bearing fault. with resonance demodulation technology, the electric resonator which resonant frequency is much higher than normal vibration frequency and l
22、imited high-harmonic frequency is designed. therefore, it can effectively restrain the low-frequency signal including normal vibration signal. the resonance response magnifies the signal amplitude of the impulse signal and the time of its oscillation islonger, thus the fault signal is broadened in t
23、he time domain signal. after the envelope detection and low-pass filter, the low-frequency resonance demodulation signal with high signal-to-noise ratio is exported. in the signal processing system shown in figure 2, the bearing component brings resonance under the impact, form the continuous attenu
24、ation oscillation. to research each attenuation oscillation, we can see that its frequency is the natural frequency of bearing components, the amplitude of attenuation oscillation is relate to intensity of fault impact. the amplitude of envelope signal of the attenuation oscillation reflects the siz
25、e of the fault, and the repeat frequency of the envelope depends on the fault location. system has the performance of anti-jamming of the low frequency vibration, high signal-to-noise ratio. c. envelope detectiona bearing with fault in the course of rolling will bring regular vibration. different fa
26、ult has different character frequency. the character frequency system detecting is the frequency of the signal envelope (the frequency which is accrued by the collision of the fault on bearing element), not the vibration frequency of the bearing. when we analyze the fault signal, the resonant freque
27、ncy (carrier wave) must be removed by envelope demodulation. because the envelope signal has fully included all information of the fault, removing carrier wave will not have any adverse impact on the analysis.keyboardliquid crystal displaybearing temperatureand air temperaturedifferential amplifierc
28、omposite sensorvibration signal amplifierfrequency band filterenvelop detectionlow frequency pass filterdigital signal processor dsp tms320lf2407aserial communicationalarmfig.3 the hardware block diagram of the bearing fault monitoringiv. hardware and software designthe hardware block diagram of the
29、 monitor for the bearing fault is shown in fig. 3. the circuit includes two parts: the vibration signal pretreatments and the bearing state analysis. the signal preprocessing part fulfills the amplification, conversion, resonance demodulation of the signal; the bearing state analysis part fulfills s
30、pectrum analysis of the signal, correlation method processing, fault grading processing, the bearings status report and communicating with peripheral equipment and so on.there are mainly three kinds of fft algorithm to realize in dsp: (1) only including addition and subtraction operations without op
31、erations of the plural rotation factor; (2) including the operation of the plural rotation factor; (3) the operation of bits location inversion. after data is processed by this way, the workload of vibration component calculation in dsp is reduced evidently. the real-time capacity of system response
32、 can be advanced.modularization design is adopted in the design of the software, which includes collections of the vibration signal and the temperature increment signal, a/d conversions, data pretreatments, fft transforms, calculations of the power spectrum, judgments of the fault grading, saves of
33、the data, displays of the data and transmissions of the data. the task dispatch is carried through by the way of event triggers and time triggers. to remove the interference, the “correlation means” processing to the results of fft transform is carried out, which assure the fault signal picked up ef
34、fectively.v. conclusionfft methods of vibration signal is adopted in system design,at same time differential temperature measurement methods is added into system to judge synthetically. the high capability dsp completes signal processing. this system can commendably satisfy the requirement for real-
35、time processing. it monitors the signal of vibrations and temperatures with combining locomotive monitor and ground analysis. the earlier diagnosis and alarm for locomotive bearings fault can be given in order to assure locomotive running safely.references1 wang dezhi,the diagnosis and maintain of r
36、olling bearingm,beijing: china railway publishing house, 1994, 2 shi huafeng,yin guohua,etc,fault diagnosis of locomotive bearingj,electric drive for locomotive, 2004,(2): 4043, 3 mei hongbin,the libration monitoring and diagnosis of rolling bearingm,beijing:china machine press,1996, 4 mei hongbin,t
37、he fault diagnosis for rolling bearings using envelope analysis,bearing,1993 ,(8):3034, 5 feng gengbin,the libration diagnosis technology of the locomotive faultm,beijing: china railway publishing house,1994. 6 jiang simi. the hardware exploiture of tms320lf240x dsp. beijing: china machine press, 20
38、03. 7 qing yuan science and technology. the application design of tms320lf240xds. beijing: china machine press, 2003. 譯文:基于dsp技術(shù)為機(jī)車(chē)軸承設(shè)計(jì)故障診斷監(jiān)控系統(tǒng)摘要滾動(dòng)軸承是機(jī)車(chē)運(yùn)行組件的關(guān)鍵部件之一,因?yàn)樗苯雨P(guān)系到機(jī)車(chē)的性能和安全。在本文章中,監(jiān)控系統(tǒng)為機(jī)車(chē)軸承基于dsp tms320lf2407a的設(shè)計(jì)。這個(gè)系統(tǒng)使用振動(dòng)分析方法來(lái)診斷滾動(dòng)軸承的故障。它是在全面的共振解調(diào)和快速傅立葉變換技術(shù)基礎(chǔ)上,采用”相關(guān)的方法”來(lái)處理fft的結(jié)果。它有效的提高了軸承故障監(jiān)控系統(tǒng)
39、的反應(yīng)特性,靈敏度,辨別和測(cè)量精度,它可以預(yù)測(cè)火車(chē)頭運(yùn)行中的故障和監(jiān)測(cè)瞬態(tài)故障。關(guān)鍵詞: 共振解調(diào)技術(shù);數(shù)字信號(hào)處理器;相關(guān)方法1引言列車(chē)有較高的安全需求是因?yàn)樗乃俣仍诓粩嗵岣?。軸承故障是造成多樣的交通事故和影響鐵路安全的主要因素之一。目前,鐵路系統(tǒng)通常采用軸承溫度探測(cè)器來(lái)監(jiān)察機(jī)車(chē)軸承的狀況。理論分析和大量的實(shí)踐證明,軸承溫度探測(cè)器可以在一定程度上防止意外發(fā)生,但大部分的軸承故障對(duì)溫度是不敏感的。當(dāng)軸承的溫度超過(guò)范圍系統(tǒng)將發(fā)出警報(bào),但不幸的是這時(shí)候軸承損傷已經(jīng)發(fā)生,甚至是事故已發(fā)生。因此,為了更早期更準(zhǔn)確的找到故障, 必須采用更先進(jìn)的監(jiān)測(cè)系統(tǒng)。大部分的軸承故障對(duì)振動(dòng)信號(hào)非常的敏感。故障可能會(huì)
40、導(dǎo)致軸承的振動(dòng)增加。經(jīng)分析和處理結(jié)果表明與監(jiān)測(cè)軸承溫度相比振動(dòng)信號(hào)比溫度的手段有更多的優(yōu)勢(shì)。2系統(tǒng)的組成和工作過(guò)程根據(jù)需要,監(jiān)視器的軸承故障監(jiān)測(cè)系統(tǒng)為機(jī)車(chē)軸承配置了兩套偵測(cè)系統(tǒng):itineration檢測(cè)和固定的檢測(cè)。 itineration檢測(cè)是用在正常情況條件下,而固定檢測(cè)用在軸承故障的連續(xù)檢測(cè)。這個(gè)系統(tǒng)采用特殊復(fù)合傳感器在同一時(shí)間收集軸承的振動(dòng)和溫度信號(hào)。經(jīng)過(guò)數(shù)據(jù)處理,將獲得相應(yīng)的故障水平和上升了的溫度。在這個(gè)系統(tǒng)中設(shè)計(jì)數(shù)據(jù)采集單元。報(bào)警信息通過(guò)接口會(huì)傳送至所有的車(chē)廂,使工作人員可以及時(shí)的處理,與此同時(shí),故障數(shù)據(jù)和列車(chē)的相關(guān)信息如目前的位置和速度將通過(guò)全球定位系統(tǒng)轉(zhuǎn)交給派遣中心,派遣中心
41、將采用相應(yīng)的措施.該系統(tǒng)方框圖如圖1。圖1 系統(tǒng)方框圖調(diào)度中心gsm系統(tǒng)工業(yè)計(jì)算機(jī)文書(shū)資料儀器的故障診斷儀器的故障診斷儀器的故障診斷.3為監(jiān)控系統(tǒng)設(shè)計(jì)的關(guān)鍵技術(shù)3.1頻譜分析在正常情況下,滾動(dòng)軸承的各部分(內(nèi)圈,外圈,滾動(dòng)體,保持架)將保持相對(duì)穩(wěn)定的工作狀態(tài)。如果一些元素的表面(保持架除外)已有裂縫,而且這些裂縫在相鄰表面也有,這時(shí)瞬時(shí)脈沖振動(dòng)必須開(kāi)啟。假設(shè)在軸承中滾動(dòng)體的數(shù)量為z;滾動(dòng)體的直徑為d;軸承的內(nèi)圈和外圈的平均直徑為d;軸承的頻率是。假設(shè)內(nèi)圈是固定的,外圈是回轉(zhuǎn)的,振動(dòng)頻率可以通過(guò)不同軸承零件的表面缺陷得到。這些頻率可以被稱(chēng)為內(nèi)圈,外圈和滾動(dòng)體的特色故障頻密程度。3.2共振解調(diào)技術(shù)
42、我們根據(jù)軸承零件的共振可以收集振動(dòng)信號(hào),并使用包絡(luò)線(xiàn)探測(cè)器檢測(cè)故障信號(hào)的包絡(luò)線(xiàn), 包絡(luò)線(xiàn)探測(cè)器可以充分的分析故障的性質(zhì),這就是”共振解調(diào)技術(shù)”。一個(gè)零件的表面,如滾動(dòng)軸承的內(nèi)圈,外圈和滾動(dòng)體極易在運(yùn)作的過(guò)程中損壞(如點(diǎn)蝕,剝落,裂縫和劃痕等)。如果一些軸承零件的表面在操作過(guò)程中有局部損傷和壓力機(jī)故障斑點(diǎn),必然會(huì)給操作帶來(lái)影響。如果影響持續(xù)的時(shí)間很短,而且能源分歧的頻率范圍是廣泛的,那么振動(dòng)頻率的能源與范圍是小的。由于帶寬的寬的脈沖,它理所應(yīng)當(dāng)?shù)陌斯逃懈哳l率的振動(dòng),通過(guò)滾動(dòng)軸承的內(nèi)圈,外圈,滾動(dòng)體和保持架的固有頻率。共振解調(diào)信號(hào)被分離是通過(guò)帶通濾波器的中心頻率和它的固有頻率相等實(shí)現(xiàn)的。然后包絡(luò)線(xiàn)解調(diào)是通過(guò)有衰解振動(dòng)波使用的軟件或電路開(kāi)展的,抹掉高頻率衰解振動(dòng)中的高頻成分。我們只獲得低頻包絡(luò)信號(hào)的故障特征的信息。包絡(luò)信號(hào)的頻譜分析
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